Conveyor system and method of laterally displacing articles

ABSTRACT

A conveyor system and method of laterally displacing articles includes a conveyor defining a conveying surface and conveying articles in a longitudinal direction with the conveying surface. A diverting assembly is positioned diagonally at least partially across the conveying surface. The diverting assembly travels generally vertically between a non-actuated position below the conveying surface and an actuated position extending above the conveying surface. The diverting assembly has a diverting surface that is adapted to laterally displace articles on the conveying surface when in the actuated position.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. provisional patentapplication Ser. Nos. 61/281,128, filed on Nov. 13, 2009, and61/323,131, filed on Apr. 12, 2010, the disclosures of which are herebyincorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

The present invention is directed to a conveyor system and method and,in particular, to a conveyor system and method for positively displacingarticles being conveyed on a conveying surface.

Laterally displacing conveyor systems laterally displace articlestravelling on a conveying surface. One such conveyor system is asortation system that diverts articles off the conveying surface to aselect spur. The spur can be a powered takeaway conveyor, gravitytakeaway conveyor, chute, or the like. One type of sortation system is apositive displacement sorter. A positive displacement sorter utilizessome type of member to affirmatively guide the article being divertedoff of the conveying surface in a manner that reduces the likelihoodthat an article could overshoot the diverter and, therefore, fail to bediverted. Divert failures are detrimental to efficient operation of thesortation system.

SUMMARY OF THE INVENTION

A conveyor system and method of laterally displacing articles, accordingto an aspect of the invention, includes a conveyor defining a conveyingsurface for conveying articles in a longitudinal direction and adiverting assembly positioned diagonally at least partially across theconveying surface. The diverting assembly is generally verticallymoveable between a non-actuated position below the conveying surface andan actuated position extending above the conveying surface to laterallydisplace articles on the conveying surface.

The diverting assembly may include a vertically oriented belt. Thediverting assembly may further include a base and a plurality of rollerssupported by the base with the rollers reeving the belt.

A conveyor system and method of laterally displacing articles, accordingto another aspect of the invention, includes a conveyor defining aconveying surface for conveying articles in a longitudinal direction anda diverting assembly positioned diagonally at least partially across theconveying surface. The diverting assembly is generally verticallymoveable between a non-actuated position below the conveying surface andan actuated position extending above the conveying surface. Thediverting assembly is configured to laterally displace articles on saidconveying surface when in the actuated position. The diverting assemblyincludes a base, a plurality of rollers supported by the base and avertically oriented belt reeved about the rollers. A plurality ofvertically oriented posts extend downwardly from the base. A pluralityof stationary blocks facilitate vertical reciprocating motion of one ofthe posts with one of the blocks.

The base may include an upper plate and a lower plate, with each of theposts passing through the lower plate and connected at the upper plate.The plurality of rollers may be mounted to the upper plate and/or thelower plate. An actuator may selectively elevate and lower the divertingassembly and may do so with controlled acceleration.

One of the rollers may be a drive roller for propelling the belt. Astationary motor may drive the drive roller and a coupling may couplethe motor with the drive roller. The coupling may be a flexible shaft ora spline. The coupling may be a flexible shaft having a takeoff assemblybetween the flexible shaft and the motor. The takeoff assembly mayinclude a sheave connected with an end of the flexible shaft and a hightorque drive between the motor and the sheave.

The diverting assembly may be made up of a plurality of divertingmembers, each having a vertically oriented driven belt. A plurality offlexible shafts may each drive the belt for one of the divertingmembers. A plurality of sheaves may each be connected with one of theflexible shafts and with the high torque drive. Another conveyor surfacemay be adjacent to the conveying surface. One of the flexible shafts maydrive the another conveying surface.

A conveyor system and method of laterally displacing articles, accordingto another aspect of the invention, includes a conveyor defining aconveying surface for conveying articles in a longitudinal direction anda plurality of diverting members aligned with each other diagonally atleast partially across the conveying surface. The diverting membersindependently travel generally vertically between a non-actuatedposition below the conveying surface and an actuated position extendingabove the conveying surface. The diverting members are configured tolaterally displace articles on the conveying surface when in theactuated position. A control is configured to independently actuate thediverting members.

The control may actuate an upstream one of the diverting members beforeactuating a downstream one of the diverting members to displace anarticle on the conveying surface. The control may deactuate the upstreamone of the diverting members before deactuating the downstream one ofthe diverting members. There may be a plurality of upstream divertingmembers and a plurality of downstream diverting members with theupstream diverting members diverging upstream from each other and thedownstream diverting members diverging downstream from each otherthereby defining a cross configuration. The control may divert articleslaterally in one direction by actuating one side of the crossconfiguration defined by an upstream diverting member and an aligneddownstream diverting member and divert articles laterally in an oppositedirection by actuating the other side of the cross configuration definedby the other upstream diverting member and an aligned downstreamdiverting member. A portion of one of the downstream diverting membersmay be positioned between an upstream diverting member and alignedopposition diverting member. The control may divert articles laterallyin the one direction by actuating that downstream diverting member alongwith the upstream diverting member and aligned opposite the downstreamdiverting member.

A conveyor system and method of laterally displacing articles, accordingto another aspect of the invention, includes a conveyor defining aconveying surface for conveying articles in a longitudinal direction anda diverting assembly positioned diagonally at least partially across theconveying surface. The diverting assembly travels generally verticallybetween a non-actuated position below the conveying surface and anactuated position extending above the conveying surface. The divertingassembly has a diverting surface to laterally displace articles on theconveying surface when in the actuated position and a motor for drivingthe diverting surface. The motor is stationary and including a couplingbetween the motor and the diverting surface.

The coupling may be a flexible shaft or a spline. The coupling may be aflexible shaft that further includes a takeoff assembly between theflexible shaft and the motor. The takeoff assembly may include a sheaveconnected with an end of the flexible shaft and a high torque drivebetween the motor and the sheave. The diverting assembly may include aplurality of diverting members, each having a diverting surface. Aplurality of flexible shafts may be provided, each driving the divertingsurface for one of the diverting members. A plurality of sheaves may beprovided, each connected with one of the flexible shafts and with thehigh torque drive. Another conveyor may be provided having anotherconveying surface that is generally adjacent to the conveying surface.One of the flexible shafts may drive the other conveying surface.

A conveyor system and method of laterally displacing articles, accordingto another aspect of the invention, includes a plurality of conveyingsections, each having a conveying surface for conveying articles andpropulsion system for propelling the conveying surfaces. The propulsionsystem may include a motor and a plurality of flexible drive shafts,each extending from the motor to one of the conveying sections to propelthe conveying surface of that conveying section.

One of the conveying sections may be a reciprocating conveying member.The reciprocating conveying member may be in the form of a diverter thatis vertically moveable between a diverting position and a non-divertingposition with the conveying surface of the diverter being a divertingsurface, such as a vertically oriented belt. Another of the conveyingsections may be a take-away conveyor for conveying articles diverted bythe reciprocating conveying member.

A conveyor system and method of laterally displacing articles, accordingto yet another aspect of the invention, includes a conveying surface forconveying articles that is defined by a plurality of rollers, eachhaving an axle. A frame is included and a plurality of axle retainersare connected with the frame Each of the axle retainers has a base and aplurality of axle retaining openings that are each adapted to receivingan end of one of the axles. At least two of the openings are atdifferent angles to said base. In this manner, the axle retainers arecapable of mounting rollers at more than one angle to the frame.

The axle retainers and the frame may have complimentary surfaces thatallow the axle retainers to be mounted at different orientations to theframe to change which of the retaining openings is used to retain one ofthe axles. The complementary surfaces may be in the form of T-shapedextensions of the axle retainers and vertical slots in the frame toreceive the extensions. The T-shaped extensions may be press-fit intothe slots in order to maintain the axle retainers connected to theframe. The axle retainers may be used with a vertically reciprocatingdiverter that reciprocates between a non-diverting position below theconveying surface and a diverting position at least partially above theconveying surface. The frame may extend along at least one side of thediverter. In this manner, the diverter can be mounted at differentangles with respect to said conveying rollers.

These and other objects, advantages and features of this invention willbecome apparent upon review of the following specification inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a conveyor system according to anembodiment of the invention one diverting assembly in a diverting stateand another diverting assembly in a non-diverting state;

FIG. 2 is a perspective view of the conveying system of FIG. 1 takenfrom the opposite lateral direction thereof with a portion of theconveying surface removed to reveal internal details thereof;

FIG. 3 is a top plan view of the conveyor system in FIG. 1;

FIG. 4 is a side elevation of a diverting assembly;

FIG. 5 is a sectional view taken along the lines V-V in FIG. 4;

FIG. 6 is a sectional view taken along the lines VI-VI in FIG. 4;

FIG. 7 is a sectional view taken along the lines VII-VII in FIG. 4;

FIG. 8 is a top plan view of a diverting member;

FIG. 9 is a sectional view taken along the lines IX-IX in FIG. 8;

FIG. 10 is a sectional view taken along the lines X-X in FIG. 8;

FIG. 11 is an end elevation of a propulsion system;

FIG. 12 is a side elevation of the propulsion system in FIG. 11;

FIG. 13 is a sectional view taken along the lines XIII-XIII in FIG. 11;

FIG. 14 is a sectional view taken along the lines XIV-XIV in FIG. 11;

FIG. 15 is the same view as FIG. 11 of an alternative embodimentthereof;

FIG. 16 is the same view as FIG. 11 of another alternative embodimentthereof;

FIGS. 17 a and 17 b illustrate a mode of operation of an embodiment ofthe invention;

FIG. 18 is the same view as FIG. 2 of an alternative embodiment of aconveyor system with a portion of the conveying surface removed toreveal internal details thereof;

FIG. 19 is a top plan view of the conveyor system in FIG. 18;

FIG. 20 is a sectional view taken along the lines XX-XX in FIG. 19;

FIG. 21 is a sectional view taken along the lines XXI-XXI in FIG. 19;

FIG. 22 is a sectional view taken along the lines XXII-XXII in FIG. 19;

FIG. 23 is an enlarged elevation of the area indicated at XXIII in FIG.22;

FIG. 24 is a top plan view of an actuator;

FIG. 25 is an enlarged top plan view of the area indicated at XXV inFIG. 19;

FIG. 26 is a side elevation of a diverting member;

FIG. 27 is a perspective view of an axle retainer;

FIG. 28 is a sectional view taken along the lines XXVIII-XXVIII in FIG.27;

FIG. 29 is a side elevation of the axle retainer in FIG. 27;

FIG. 30 is another perspective view of the axle retainer in FIG. 27taken from a different direction;

FIG. 31 is a perspective view of an alternative embodiment of a conveyorsystem;

FIG. 32 is a top plan view of the conveyor system in FIG. 31;

FIG. 33 is the same view as FIG. 32 showing a finger guard;

FIGS. 34 a-34 c are a top plan view of another alternative embodiment ofa conveyor system showing various modes of operation thereof; and

FIG. 35 is the same general view as FIG. 2 of yet another alternativeembodiment of a conveyor system.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings and the illustrative embodiments depictedtherein a conveyor system 20 includes a conveyor 22 that has a conveyingsurface 24 for conveying articles in a longitudinal direction and adiverting assembly 26 positioned diagonally across conveying surface 24(FIGS. 1-16). Diverting assembly 26 travels, or reciprocates, generallyvertically between a non-actuated position illustrated in FIG. 1 belowconveying surface 24 and an actuated position extending above conveyingsurface 24. Diverting assembly 26 may be made up of a plurality ofdiverting members 30 a, 30 b . . . 30 n that are independentlyactuatable. In FIG. 1, diverting member 30 a is shown in a non-actuatedposition and diverting member 30 b is shown in an actuated position.However, diverting assembly 26 may be made up of only one divertingmember of a plurality of diverting members that are actuatable inunison. Diverting assembly 26 is configured to laterally displacearticles that are being conveyed on conveying surface 24 when thediverting assembly is in its actuated position. It may be used toreposition articles on the conveying surface or, in the embodimentillustrated in FIGS. 1 and 2, it may be used to divert articles off theconveying surface to a takeaway spur, such as a takeaway poweredconveyor 28. In the illustrated embodiment, diverting assembly 26 is atan angle of 30 degrees from the longitudinal direction of travel ofconveying surface 24, as illustrated in FIG. 3. However, it may be atany desired angle, such as between 20 degrees and 45 degrees, or thelike. While conveyor system 20 is illustrated for use with distributionof articles, such as cases of goods being shipped, for example, fromwarehouses to retail outlets, it can also be used in parcelapplications, such as express shipping, as well as user-packed luggagesortation at airports, and the like.

Diverting members 30 a, 30 b . . . 30 n of diverting assembly 26 eachhave a vertical diverting surface, which may be a powered divertingsurface, such as provided by a powered vertically oriented belt 32.Alternatively, diverting member 30 may have a passive diverting surface,such as free-running wheels, an anti-friction surface, or the like. If apowered diverting surface is used, the speed of the diverting surfacemay have a longitudinal component that has approximately the same speedas that of conveying surface 24 in order to maintain the forwardvelocity of articles being diverted. Each diverting assembly 26 includesa base 34 that vertically reciprocates in a guide frame 36 and aplurality of rollers 38 supported by base 34. Rollers 38 reeve verticalbelt 32 and provide support or backing to the belt when contacted by anarticle being diverted. Each diverting member 30 includes a plurality ofvertically oriented posts 40 extending downwardly from base 34 and aplurality of stationary blocks 42, made from a polymer, such as UHMW, orthe like, mounted to guide frame 36, each for facilitating verticalreciprocating motion of one of posts 40. Base 34 includes an upper plate44 and a lower plate 46 interconnected by one or more sidewalls 47. Eachpost 40 passes through an opening in lower plate 46 sized just largerthan the post and is connected with upper plate 44. This provides spacedapart support to posts 40 to be able to withstand the shock of contactby the articles against diverting member 30. Biasing members, such asextension springs 45, assist in returning diverting member 30 to anon-actuated position.

Rollers 38 are mounted to upper plate 44, lower plate 46, or both. Oneof the rollers is a drive roller 48 for propelling belt 32 (FIG. 10).Roller 48 is an extension of a shaft 52 that is rotatably supported by apair of bearings 54 to sidewall 47. An opposite end of shaft 52 definesa socket 56 whose purpose will be explained in more detail below. Belt32 is supported by an opposite idler pulley 49 connected with sidewalls47 by an arm 50. A tensioner, such as a spring, 51 applies outward forceon arm 50 in order to apply a tension on belt 32 via idler pulley 49.Roller 48, and, hence, the diverting surface defined by belt 32, isdriven by a propulsion system 58. Propulsion system 58 includes a motor60 and a coupling 62 for coupling motor 60 to roller 48. While motor 60is illustrated as an AC electric motor that is driven by a variablefrequency drive (not shown), it could be a DC electric motor, apneumatic motor, a hydraulic motor, or the like. Motor 60 is stationarywith coupling 62 accommodating relative motion between roller 48 andmotor 60 as diverting members 30 a, 30 b . . . 30 n reciprocate up anddown.

In the illustrated embodiment, coupling 62 includes a flexible shaft 64,although other forms of coupling, such as a spline, may be used.Flexible shaft 64 may be a twisted power wire core with a covering ofthe type that is commercially available, such as from Otto Suhner A G ofBrugg Switzerland. Coupling 62 of propulsion system 58 further includesa takeoff assembly 66 between flexible shaft 64 and motor 60 (FIG. 13).Takeoff assembly 66 may include a socket 72 connected with the outputshaft 74 of motor 60 for coupling to one end of flexible shaft 64.Alternatively, takeoff assembly 66 may include a sheave 68 that isrotatably supported by a bearing assembly 71 and connected with an endof flexible shaft 64 via a socket 76. A high torque drive 70 betweenoutput shaft 74 of motor 60 and sheave 68 rotates socket 76 and, hence,flexible shaft 64. The other end of flexible shaft 64 is connected withsocket 56 of shaft 52. In the illustrated embodiment, high torque drive70 is in the form of a cog belt, but could, alternatively, be a chain,or the like.

If diverting assembly 26 is made up of a plurality of diverting members30 a, 30 b, . . . 30 n, each having a driven vertically oriented belt32, propulsion system 58 includes a plurality of flexible shafts 64,each driving the vertical belt 32 for one of diverting members 30 a, 30b. In such arrangement, propulsion system 58 includes a socket 72connected directly to the output shaft 74 of motor 60 and a sheave 68,each connected with one of one of flexible shafts 64. Should it bedesired to have more than two diverting members, additional flexibleshafts and additional sheaves 68 may be provided in propulsion system 58and connected with output shaft 74 of motor 60 via high torque drive 70,as illustrated in FIGS. 15 and 16. Moreover, a flexible shaft 64 may beused to drive an adjacent conveyor. For example, a flexible shaft may beused to drive powered, or driven, takeaway conveyor 28 adjacentconveying surfaces 24 by another one of flexible shafts 64 connectedwith another socket 72 that is powered by high torque drive 70.

Alternatively, a flexible shaft may be used to drive a conveyor upstreamor downstream of conveyor system 20. In this manner, one motor 60 can beused to drive multiple conveying members. This reduces system cost byreducing electrical wiring, and the like. Also, it allows transmissionthrough congested areas of the system. If it be desired to drive one ofthe multiple conveying members in an opposite direction, high torquedrive 70 may be reeved differently as illustrated in FIG. 15 in which asheave 68 c is shown reeved to rotate in a different direction fromsheaves 68 a and 68 b. Also, if desired, a socket 76 and flexible shaft64 could extend in an opposite direction from bearing assembly 71. Also,if it be desired to drive one flexible shaft 64 at a different speedfrom other flexible shafts, the diameter of sheave 68 could be selectedin a manner that would be understood by the skilled artisan. Also, oneor more sheaves 68 could incorporate an electrically operated clutch inorder to allow control 98 to selectively rotate the associated flexibleshaft 64.

In the illustrated embodiment, conveying surface 24 is a powered rollerconveying surface. It should be understood that other types of conveyingsurfaces, such as provided by gravity conveyor, belt conveyor, or thelike, may be used. Conveying surface 24 is defined by a plurality ofrollers 78 upstream and downstream of diverting assembly 26. Conveyingsurface 24 is further defined by a plurality of rollers 80 a on onelateral side of diverting assembly 26 and a plurality of rollers 80 b onan opposite lateral side of diverting assembly 26. Rollers 80 a and 80 bare of various lengths to accommodate the diagonal orientation ofdiverting assembly 26. Guide frame 36 includes a series of tabs 82, eachdefining a hexagonal hole 84 to receive the axle of one end of rollers80 a, 80 b with an opposite end of the rollers mounted to side framemembers 23. Rollers 78 and either rollers 80 a or 80 b are propelled bya roller drive system 85 made up of an endless belt 86 of the typemarketed by the Nitta Corporation. Belt 86 may propel the rollersutilizing the principles disclosed in commonly assigned U.S. PatentApplication Publication No. 2009/0101475 entitled ROLLER TRANSPORTCONVEYOR AND METHOD, the disclosure of which is hereby incorporatedherein by reference. Roller drive system 85 may further include asecondary endless belt 88 and a transfer roller 90. The rollers 80 a, 80b that are not propelled by belt 86 may be propelled by secondaryendless belt 88, again using the principles disclosed in the '475 patentapplication publication. However, secondary endless belt 88 may bepropelled by transfer roller 90 that transfers the motion of endlessbelt 86 to belt 88. Transfer roller 90 is rotated by a power tap off 92utilizing the principles disclosed in commonly assigned patentapplication Ser. No. 12/891,868, filed Sep. 28, 2010, by Brayman et al.for a BELT DRIVE CONNECTOR WITH POWER TAP OFF, the disclosure of whichis hereby incorporated herein by reference. It should be understood thatother techniques could be utilized to propel rollers 78, 80 a and 80 b,including utilizing motorized rollers, or the like.

As previously set forth, diverting member 30 is guided in verticallyreciprocating motion by posts 40 riding in blocks 42. Diverting member30 is elevated by at least one actuator 94 between guide frame 96 andbase 34. In the illustrated embodiment, actuator 94 is a pneumaticcylinder that is controlled by a pneumatic valve 96 that responds toelectrical signals from a control 98. However, actuator 94 could be anelectrical solenoid, hydraulic cylinder, or the like.

Operation of conveyor system 20 is as follows. With articles beingtransported by conveying surface 24, a higher level control instructscontrol 98 to transfer a particular article to takeaway conveyor 28. Thearticle may be identified by a bar code, an RFID tag, or the like, onthe article. When the article approaches diverting assembly 26, assensed by an article sensor of the type known in the art, one or morediverting members 30 a, 30 b . . . 30 n are elevated by actuator(s) 94.Vertical transfer belt 32 may be continuously running so that, when thearticle makes contact with diverting assembly 26, the forward motion ofthe article being propelled by conveying surface 24 in combination withthe motion of transfer belt 32 laterally displaces the article acrossconveying surface 24 onto takeaway conveyor 28. However, belt 32 could,alternatively, be powered only when needed to make a divert.

While two or more diverting members 30 may be actuated concurrently,articles may be spaced even closer together if they are actuated anddeactuated sequentially as follows. By reference to FIGS. 17 a and 17 b,a leading article designated A is shown as not being diverted and,therefore, passes over diverting assembly 26 which remains retracted.Once article A passes upstream diverting member 30 a, diverting member30 a is actuated in order to initiate the divert of an article B, asseen in FIG. 17 a. Upstream diverting member 30 a can be actuated eventhough article A is still positioned over downstream diverting member 30b. After article A clears both diverting members 30 a, 30 b, thedownstream diverting member 30 b is actuated to complete the divertingof article B, as seen in FIG. 17 b. Once downstream diverting member 30b takes over the diverting of article B, upstream diverting member 30 acan be retracted as also seen in FIG. 17 b. This allows an article C tofollow closer to article B than if upstream diverting member 30 a wereto remain actuated until article B is fully diverted because article Ccan pass over retracted upstream diverting member 30 a while downstreamdiverting member 30 b is completing the diverting of article B.

As is understood by the skilled artisan, the throughput of a conveyorsystem is inversely proportional to the gaps between articles. Byallowing articles to be conveyed closer together, conveyor system 20provides an increase in throughput as a result of the independentsequential operation of diverting members 30 a, 30 b. In the illustratedembodiment, conveyor system 20 may be capable of sorting up to about 40standard cartons per minute (CPM) with diverting members 30 a, 30 bactuated together and up to about 80 CPM with diverting members 30 a, 30b actuated sequentially in the manner previously described. While onlytwo diverting members 30 a, 30 b are illustrated, three or more may beutilized to provide an even greater control over article diverting andthereby smaller article spacing.

Other applications for conveyor system 20 are possible. For example, byproviding diverting members 30 a, 30 b . . . 30 n in different lengthsand arranging them in parallel rather than in line with each other, theymay be used to provide center alignment of articles being inducted, forexample, to a bidirectional sorter. Such sorters sort articles travelingdown the middle of the sorter rather than being justified to one side ofthe sorter. The diverting members may be selectively actuated, such asbased on the size and location of an article to displace the articletoward the center of the conveying surface. Other applications will beapparent to the skilled artisan.

In an alternative embodiment, a conveyor system 120 includes a conveyor122 that has a conveying surface 124 for conveying articles in alongitudinal direction and a diverting assembly 126 positioneddiagonally across conveying surface 124 (FIGS. 18-29). Divertingassembly 126 travels, or reciprocates, generally vertically between anon-actuated position, similar to diverting member 30 a illustrated inFIG. 1, below conveying surface 124 and an actuated position, similar todiverting member 30 b illustrated in FIG. 1, extending above conveyingsurface 124. Diverting assembly 126 is configured to laterally displacearticles that are being conveyed on conveying surface 124 when thediverting assembly is in its actuated position. It may be used toreposition articles on the conveying surface or it may be used to divertarticles off the conveying surface to a takeaway spur, such as atakeaway powered conveyor 128. While two takeaway conveyors 128 areshown on opposite lateral sides of conveying surface 124 in FIG. 19, itshould be understood that the embodiment illustrated in FIG. 19 istypically only capable of diverting in one lateral direction or theother depending upon the direction of movement of conveying surface 124.

In the illustrated embodiment, diverting assembly 126 is at an angle of30 degrees from the longitudinal direction of travel of conveyingsurface 124, as illustrated in FIGS. 18 and 19. However, it may be atany desired angle, such as between 20 degrees and 45 degrees, or thelike, as will be discussed in more detail below. While conveyer system120 is illustrated for use with distribution of articles, such as casesof goods being shipped, for example, from warehouses to retail outlets,it can also be used in parcel applications, such as express shipping, aswell as user-packed luggage sortation at airports, and the like.

Diverting assembly 126 includes one or more diverting members 130 a, 130b . . . 130 n each having a vertical diverting surface, which may be apowered diverting surface, such as a powered vertically oriented belt132. Alternatively, diverting member 130 may have a passive divertingsurface, such as free-running wheels, an anti-friction surface, or thelike. If a powered diverting surface is used, the speed of the divertingsurface may have a longitudinal component that has approximately thesame speed as that of conveying surface 124 in order to maintain theforward velocity of articles being diverted. Each diverting assembly 126includes a base 134 that vertically reciprocates in a guide frame 136and a plurality of rollers 138 supported by base 134. Rollers 138 reevevertical belt 132 and provide support or backing to the belt whencontacted by an article being diverted. Each diverting member 130includes a plurality of vertically oriented posts 140 extendingdownwardly from base 134 and a plurality of stationary blocks 142, madefrom a polymer, such as UHMW, or the like, mounted to guide frame 136,each for facilitating vertical reciprocating motion of one of posts 140.Base 134 includes an upper plate 144 and a lower plate 146interconnected by one or more sidewalls 147. Each post 140 passesthrough an opening in lower plate 146 sized just larger than the postand is connected with upper plate 144. This provides spaced apartsupport to posts 140 to be able to withstand the shock of contact by thearticles against diverting member 130.

Diverting member 130 is elevated by an actuator 194 between guide frame136 and base 134. In the illustrated embodiment, actuator 194 includes apneumatic cylinder 195 that is controlled by a pneumatic valve that maybe similar to valve 96 that responds to electrical signals from acontrol, similar to control 98. However, actuator 194 could be anelectrical solenoid, hydraulic cylinder, or the like, instead ofpneumatic cylinder 195. Actuator 194 rotates an arm 197 which is capableof applying controlled acceleration to base 134 during both the raisingand lowering of diverting member 130. A terminal end 199 of arm 197translates the linear motion of cylinder 195 to a sinusoidal motion,which is applied to base 134 via a roller 200. More particularly, evenif the linear motion of cylinder 195 involves an abrupt acceleration,the vertical motion imparted to base 134 by arm 197 will have limitedacceleration according to a sinusoidal function, as would be understoodby the skilled artisan.

Rollers 138 are mounted to upper plate 144. One of the rollers is adrive roller 148 for propelling belt 132. Roller 148 is supported by anarm 150 supported by sidewalls 147. Roller 148 is an extension of ashaft 152 that is rotatably supported by a pair of bearings 154 to arm150. An opposite end of shaft 152 defines a socket 156 whose purposewill be explained in more detail below. A tensioner 151 applies outwardforce on arm 150 in order to apply a tension on belt 132. Roller 148,and, hence, the diverting surface defined by belt 132, may be driven bya propulsion system of the same type as propulsion system 58.

In the illustrated embodiment, diverting assembly 126 is made up of aplurality of diverting members 130 a, 130 b, each having a drivenvertically oriented belt 132. In such arrangement, the propulsion systemincludes a plurality of flexible shafts 164, each driving the verticalbelt 132 for one of diverting members 130 a, 130 b. In the illustratedembodiment, conveying surface 124 is a powered roller conveying surface.It should be understood that other types of conveying surfaces, such asprovided by a gravity conveyor, belt conveyor, or the like, may be used.Conveying surface 124 is defined by a plurality of rollers 178 upstreamand downstream of diverting assembly 126. Conveying surface 124 isfurther defined by a plurality of rollers 180 a on one lateral side ofdiverting assembly 126 and a plurality of rollers 180 b on an oppositelateral side of diverting assembly 126 that are similar to rollers 80 aand 80 b. Rollers 180 a and 180 b are of various lengths to accommodatethe diagonal orientation of diverting assembly 126. Rollers 178 andeither rollers 180 a or 180 b may be propelled by a roller drive system185 including an endless belt 186 that is similar to belt 86 and whichmay be driven in the manner previously described with respect to belt86. Roller drive system 185 may further include a secondary endless belt188. The rollers 180 a, 180 b that are not propelled by belt 186 may bepropelled by secondary endless belt 188 that is similar to belt 88 anddriven in a similar manner as previously described. Operation ofconveyor system 120 is similar to the operation of conveyor system 20 aspreviously described.

Each roller 180 a, 180 b includes an axle, or portion of an axle,extending from each end thereof. The axle on one end is received in anopening, such as a hexagonally shaped opening 202 in a side framemember. The axle on the other end of each roller 180 a, 180 b issupported by an axle retainer 204. Axle retainer 204, which may bemolded from a conventional polymeric material, has a base 206 that isadapted to be mounted to a frame, such as guide frame 136 that is onopposite sides of diverting members 130 a, 130 b. Each axle retainerfurther includes two or more axle retaining openings 208 a, 208 bextending from base 206. Each axle retaining opening 208 a, 208 b isadapted to receiving an end of one of the axles extending from a roller180 a, 180 b. Each of the axle retaining openings 208 a, 208 b is at adifferent angle to said base. In this manner, axle retainers 204 arecapable of mounting rollers at more than one angle to guide frame 136.This allows diverting assembly 126 to be mounted at different divertangles with respect to conveying surface 124 merely by changing whichaxle retaining opening 208 a, 208 b that is used to support the axles atone end of rollers 180 a, 180 b. Which axle retaining opening 208 a, 208b that is used can be selected by how each axle retainer 204 isoriented.

Axle retainers 204 and guide frame 136 have complimentary surfaces thatallow the axle retainers to be mounted at different orientations to theguide frame to change which of the retaining openings is used to retainone of said axles. The complementary surfaces are made up of T-shapedextensions 210 of base 206 of the axle retainers and vertical slots 212in the guide frame to receive extensions 210. The T-shaped extensionsare press-fit into slots 212 in order to retain axle retainers 204connected to guide frame 136. Thus, with one portion of base 206pointing upwardly, one axle retaining opening 208 a, 208 b will bepositioned to receive a roller axle. With the opposite portion of base206 pointed upwardly, the other axle retaining opening 208 a, 208 b willbe positioned to receive the roller axle.

It should be understood that axle retainers may find application otherthan with a diverting assembly 216. For example, axle retainers 304 areshown in an application in a conveyor 320 where rollers 338 are placedan different angles with respect to a conveyor side frame 336, such aswhen skewed rollers are used such as for unscrambling or aligningconveyors (FIGS. 31-33). Axle retainers 304 may conveniently include afastener portion, such as an opening 339 that receives other fastenerportions, such as threaded fasteners 341 to retain, for example, afinger guard 343. Other applications will be apparent to the skilledartisan.

In an alternative embodiment, a conveyor system 220 is capable ofbidirectional diverting to opposite lateral sides of a conveyor.Conveyor system 220 includes a plurality of diverting members 230 a, 230b, 230 c and 230 d that are arranged in a generally “X” pattern (FIG. 34a). These include a plurality of upstream diverting members 230 a, 230 band a plurality of downstream diverting members 230 c, 230 d. Upstreamdiverting members 230 a, 230 b diverge upstream from each other anddownstream diverting members 230 b, 230 d diverge downstream therebydefining a cross configuration, namely the “X” pattern. A controldiverts articles laterally in one direction by actuating one side of thecross configuration defined by one of said upstream diverting members230 a or 230 b and an aligned one of the downstream diverting members230 c or 230 d. The control diverts articles laterally in an oppositedirection by actuating the other side of said cross configurationdefined by the other of the upstream diverting members 230 a or 230 band an aligned other of the downstream diverting members 230 c or 230 d.However, in the illustrated embodiment, a portion of one of thediverting members, such as diverting member 230 d is partiallypositioned between aligned ones of the diverting members, such asdiverting members 230 b and 230 c.

In this embodiment of conveyor system 220, the control diverts articleslaterally in direction A by actuating aligned diverting members 230 aand 230 d (FIG. 34 b). However, the control diverts articles laterallyin the opposite direction B by actuating upstream diverting member 230b, aligned downstream diverting member 230 c and the other downstreamdiverting member 230 d (FIG. 34 c). The purpose of extending a portionof diverting member 230 d between aligned diverting members 230 b and230 c is to fill the gap between diverting members 230 b, 230 c thatwould otherwise be created by the four diverting members coming togetherat one point. It would be understood by the skilled artisan that thistechnique could be accomplished by extending either downstream divertingmembers 230 c or 230 d between the opposite aligned diverting members.

In yet a further embodiment, a conveyor system 320 includes a conveyingsurface 324 and a diverting assembly 326 having one or more divertingmembers 330 a, 330 b that are otherwise similar to those previouslydescribed (FIG. 35). Conveying surface 324 is made up of rollers 380 aand 380 b that are driven by a roller drive system 385. Roller drivesystem 385 is made up of a plurality of motorized rollers 387 that aremounted transverse to rollers 380 a, 380 b and drive rollers 380 a, 380b via O-rings 389 using the principles disclosed in commonly assignedU.S. Pat. No. 7,383,935 entitled MOTORIZED ROLLER TRANSVERSE DRIVE, thedisclosure of which is hereby incorporated herein by reference.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the invention.For example, the diverting assembly could be supplied in kit form to beapplied to an existing conveyor system. The invention is intended to belimited only by the scope of the appended claims, as interpretedaccording to the principles of patent law including the doctrine ofequivalents.

1. A conveyor system, comprising: a conveyor defining a conveyingsurface for conveying articles in a longitudinal direction; and adiverting assembly positioned diagonally at least partially across saidconveying surface, said diverting assembly travelling generallyvertically between a non-actuated position below said conveying surfaceand an actuated position extending above said conveying surface, saiddiverting assembly having a diverting surface that is adapted tolaterally displace articles on said conveying surface when in saidactuated position.
 2. The conveyor system as claimed in claim 1 whereinsaid diverting surface comprises a vertically oriented belt.
 3. Theconveyor system as claimed in claim 2 wherein said diverting assemblyfurther includes a base and a plurality of rollers supported by saidbase, said rollers reeving said belt.
 4. The conveyor system as claimedin claim 1 wherein said diverting assembly includes a base, a pluralityof rollers supported by said base and a vertically oriented belt, saidbelt reeved about said rollers; and a plurality of vertically orientedposts extending downwardly from said base and a plurality of stationaryblocks, each for facilitating vertical reciprocating motion of one ofsaid posts.
 5. The conveyor system as claimed in claim 4 wherein saidbase includes an upper plate and a lower plate, each of said postspassing through said lower plate and connected at said upper plate. 6.The conveyor system as claimed in claim 5 wherein said plurality ofrollers are mounted to at least one chosen from said upper plate andsaid lower plate.
 7. The conveyor system as claimed in claim 1 includingan actuator for selectively elevating and lowering said divertingassembly, said actuator elevating and lowering said diverting assemblywith controlled acceleration.
 8. The conveyor system as claimed in claim2 including a stationary motor for driving said belt and a couplingbetween said motor and said drive roller.
 9. The conveyor system asclaimed in claim 8 wherein said coupling comprises a flexible shaft or aspline.
 10. The conveyor system as claimed in claim 9 wherein saidcoupling comprises said flexible shaft and further including a takeoffassembly between said flexible shaft and said motor.
 11. The conveyorsystem as claimed in claim 10 wherein said takeoff assembly comprises asheave connected with an end of said flexible shaft and a high torquedrive between said motor and said sheave.
 12. The conveyor system asclaimed in claim 11 wherein said diverting assembly comprises aplurality of diverting members, each having a vertically oriented drivenbelt.
 13. The conveyor system as claimed in claim 12 including aplurality of said flexible shafts, each driving said belt for one ofsaid diverting members.
 14. The conveyor system as claimed in claim 13including a plurality of said sheaves, each connected with one of saidflexible shafts and with said high torque drive.
 15. The conveyor systemas claimed in claim 13 including another conveyor having anotherconveying surface adjacent said conveying surface, wherein one of saidflexible shafts drives said another conveying surface.
 16. The conveyorsystem as claimed in claim 1 including a plurality of said divertingmembers aligned with each other diagonally at least partially acrosssaid conveying surface and a control, said diverting members adapted toindependently travel generally vertically between a non-actuatedposition below said conveying surface and an actuated position extendingabove said conveying surface, said diverting members being adapted tolaterally displace articles on said conveying surface when in saidactuated position, said control configured to independently actuate saiddiverting members.
 17. The conveyor system as claimed in claim 16wherein said control actuates an upstream one of said diverting membersbefore actuating a downstream one of said diverting members to displacean article on said conveying surface.
 18. The conveyor system as claimedin claim 17 wherein said control deactuates said upstream one of saiddiverting members before deactuating said downstream one of saiddiverting members.
 19. The conveyor system as claimed in claim 16wherein said control deactuates an upstream one of said divertingmembers before deactuating a downstream one of said diverting members.20. The conveyor system as claimed in claim 16 wherein said plurality ofdiverting members include a plurality of upstream ones of said divertingmembers and a plurality of downstream ones of said diverting members,said upstream diverting members diverging upstream from each other andsaid downstream diverting members diverging downstream thereby defininga cross configuration wherein said control diverts articles laterally inone direction by actuating one side of said cross configuration definedby one of said upstream diverting members and an aligned one of saiddownstream diverting members and wherein said control diverts articleslaterally in an opposite direction by actuating the other side of saidcross configuration defined by the other of said upstream divertingmembers and an aligned other of said downstream diverting members. 21.The conveyor system as claimed in claim 20 wherein a portion of one ofsaid downstream diverting members is positioned between an upstreamdiverting member and aligned opposition one of said diverting membersand wherein said control diverts articles laterally in said onedirection by actuating said one of said downstream diverting members andsaid upstream diverting member and aligned opposite one of saiddownstream diverting members.
 22. A conveyor system, comprising: aplurality of conveying sections, each having a conveying surface forconveying articles; and a propulsion system for propelling saidconveying surfaces, wherein said propulsion system comprises a motor anda plurality of flexible drive shafts, each of said flexible drive shaftsextending from said motor to one of said conveying sections to propelthe conveying surface of that conveying section.
 23. The conveyingsystem as claimed in claim 22 wherein at least one of said conveyingsections comprises a reciprocating conveying member.
 24. The conveyingsystem as claimed in claim 23 wherein said reciprocating conveyingmember comprises a diverter that is vertically reciprocating between adiverting position and a non-diverting position and wherein saidconveying surface of said diverter comprises a diverting surface.
 25. Aconveyor system, comprising: a conveying surface for conveying articles,said conveying surface defined by a plurality of rollers, each of saidrollers comprising an axle; and a frame and a plurality of axleretainers connected with said frame, each of said axle retainers havinga base and a plurality of axle retaining openings that are each adaptedto receiving an end of one of said axles, at least two of said openingsbeing at different angles to said base, whereby said axle retainers arecapable of mounting rollers at more than one angle to said frame. 26.The conveyor system as claimed in claim 25 wherein said axle retainersand said frame have complimentary surfaces that allow said axleretainers to be mounted at different orientations to said frame tochange which of said retaining openings is used to retain one of saidaxles.
 27. The conveyor system as claimed in claim 26 wherein saidcomplementary surfaces comprise T-shaped extensions of said axleretainers and vertical slots in said frame to receive said extensions.28. The conveyor system as claimed in claim 27 wherein said T-shapedextensions are press-fit into said slots in order to maintain said axleretainers connected to said frame.
 29. The conveyor system as claimed inclaim 25 including a vertically reciprocating diverter that reciprocatesbetween a non-diverting position below said conveying surface and adiverting position at least partially above said conveying surface,wherein said frame extends along at least one side of said diverterwherein said diverter can be mounted at different angles with respect tosaid conveying rollers.
 30. A method of laterally displacing articleswith a conveyor defining a conveying surface and a diverting assemblypositioned diagonally at least partially across said conveying surface,said method comprising: conveying articles in a longitudinal directionwith the conveying surface; and moving said diverting assembly generallyvertically between a non-actuated position below said conveying surfaceto allow an article on said conveying surface to pass said divertingassembly and an actuated position extending above said conveying surfaceto laterally displace an article on said conveying surface.